Off-Road Recreational Vehicle

ABSTRACT

Embodiments relate to an off-road vehicle comprising a frame, including at least one cargo box support member, a suspension movably coupled to the frame, a passenger compartment, an engine, a transmission operatively coupled to the engine, and a cargo box. The cargo box includes a floor and a plurality of upwardly extending sidewalls, wherein at least a portion of the cargo box floor extends over the at least one cargo box support member and wherein the cargo box is removably coupled to the at least one cargo box support members and is removable from the off-road vehicle via the removal of fewer than eight fasteners.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.15/244,793, filed Aug. 23, 2016, which claims the benefit of andpriority to U.S. Provisional Application No. 62/208,805, filed Aug. 23,2015, and which application is incorporated herein by reference. A claimof priority is made.

BACKGROUND

Off-road recreational vehicles, such as side-by-side recreationaloff-highway vehicles (“ROVs”) or all-terrain vehicles (“ATVs”), arequite capable in a wide variety of riding environments and situations,whether for sport or utility purposes. The vehicles can be easy to enterand exit and easy to operate with controls and ergonomics somewhatsimilar to automobiles. However, unlike most automobiles, off-roadrecreational vehicles can be driven on harsh off-road terrain.

SUMMARY

Embodiments relate to an off-road vehicle comprising a frame, includingat least one cargo box support member, a suspension movably coupled tothe frame, a passenger compartment, an engine, a transmissionoperatively coupled to the engine, and a cargo box. The cargo boxincludes a floor and a plurality of upwardly extending sidewalls,wherein at least a portion of the cargo box floor extends over the atleast one cargo box support member and wherein the cargo box isremovably coupled to the at least one cargo box support members and isremovable from the off-road vehicle via the removal of fewer than eightfasteners.

Embodiments also relate to an off-road vehicle comprising a frame,including at least one cargo box support member, a suspension movablycoupled to the frame, a passenger compartment, an engine having anengine block, a transmission operatively coupled to the engine, and anengine cradle. The engine cradle includes a first portion extendingforwardly of the engine block and a second portion extending rearwardlyof the engine block, wherein at least a portion of the engine cradleextends under the engine block.

BRIEF DESCRIPTION OF DRAWINGS

This written disclosure describes illustrative embodiments that arenon-limiting and non-exhaustive. Reference is made to illustrativeembodiments that are depicted in the figures, in which:

FIGS. 1-41 illustrate perspective views of an off-road recreationalvehicle, according to some embodiments.

FIGS. 42-51 illustrate perspective views of drive train and enginecomponents, according to some embodiments.

FIGS. 52-53 illustrate perspective views of air handling components,according to some embodiments.

FIGS. 54-55 illustrate perspective views of steering components,according to some embodiments.

FIGS. 56-57 illustrate perspective views of a brake system, according tosome embodiments.

FIGS. 58-66, 91-92 illustrate perspective views of a suspension system,according to some embodiments.

FIGS. 67-84 illustrate perspective views of body panels, cowls, skidplates, and doors of an off-road recreational vehicle, according to someembodiments.

FIGS. 85-90, 106, and 107 illustrate perspective views a floor panel, afootwell panel, center console, upper dash, bridging dash panel, cornerupright panel, gauge panel, rear console member, and cupholder member ofan off-road recreational vehicle, according to some embodiments.

FIG. 93 illustrates a perspective view of a cooling system of anoff-road recreational vehicle, according to some embodiments.

FIGS. 94-100 illustrate perspective views a removable subframe andassociated components, according to some embodiments.

FIGS. 101-105 illustrate perspective views of trailing arm attachmentlocations formed from castings to which respective frame tubes arewelded, according to some embodiments.

DETAILED DESCRIPTION

As shown in FIG. 1 an embodiment of an off-road vehicle 10 includes aplurality of ground engaging members 50, a front suspension assembly 72(FIG. 3), a rear suspension assembly 38 (FIG. 3), a frame 12, and one ormore body panels 200. In some embodiments, the off-road vehicle 10further comprises a cargo box 202 (FIG. 68).

In some embodiments, the frame 12 includes structural members 204 (FIG.2) which are coupled together (e.g., welded, bolted, glued). Further,the structural members 204 can be tubular steel or aluminum, stampedsheet metal (e.g., steel, aluminum), hydroformed, cast, forged, orformed in any other suitable manner. The off-road vehicle 10 can be2-wheel or 4-wheel drive. Further, it can have any suitable style ofdrive system. In some embodiments, the off-road vehicle 10 is 4-wheeldrive and includes a differential one or both the front end and rear endof the off-road vehicle 10. The differentials can include optionallocking differentials or they can be open differentials, which can bemanually selectable by an operator or engaged automatically in responseto terrain conditions (e.g., wheel slip). In some embodiments, theoff-road vehicle has a limited slip differential (e.g., clutch pack,Quaife, Torsen) or any other suitable configuration (e.g., spool).

With further regard to FIG. 2, in some embodiments, the off-road vehicle10 includes a seating area 206. The seating area 206 includes one ormore seats 208. Further one or more of the seats 208 can be arranged inany configuration, such as a side-by-side configuration. Further still,the seats 208 can include bench seats, bucket seats, or a combination ofboth bench and bucket seating. In some embodiments, one or more of theseats 208, or portions thereof, are adjustable.

In some embodiments, the frame 12 includes a ROPS (roll-over protectionstructure) 210. In some embodiments, the ROPS 210 is attached to themain frame 212. As used in herein, the term “frame” 12 includes both theROPS 210 and main frame 212.

As shown in FIG. 2, in some embodiments, the off-road vehicle 10includes a steering wheel 214 which is coupled, for example via asteering linkage, to at least two of the ground engaging members 50, forexample front ground engaging members. The steering wheel 84 is coupledto the front ground engaging members (e.g., tires) in any suitable way,for example by mechanical steering linkage, electric power steering(EPS), hydraulically assisted power steering, electric power steeringwithout mechanical linkage (e.g., drive-by-wire), electric assistedpower steering ((EPAS), e.g., including pull-drift compensation, activenibble control, etc.) or in any other suitable way. Further, in someembodiments, the steering can include variable ratio steering and it canbe programmable such that the user can set the steering ratio (andrate-of-change of steering ration, if it is variable) to illicit asteering response in accordance with the user's or manufacturer'sdesires (e.g., exhibiting understeer characteristics). As further shownin FIG. 2, in some embodiments, the steering wheel 214 tilts, shown viaarrow 216, and a tilt assembly 218 includes a shock 220 to adjust thetilt configuration of the steering wheel 214.

With regard to FIG. 3, the off-road vehicle 10 includes a gear shiftselector 222. The gear shift selector 222 is coupled to the transmission224 (FIG. 42), for example via a push-pull cable 226. The off-roadvehicle 10 further includes a radiator 142 and coolant lines (or coolanthoses) 156, also shown in FIG. 93. As illustrated in FIG. 93, in someembodiments, the coolant lines 156 include a first coolant line 156 aand a second coolant line 156 b. In some embodiments, coolant flowsthrough the first coolant line 156 a from the radiator 142 to the primemover (e.g., engine 86, FIG. 4), as shown via directional arrow 228(FIG. 93). In some embodiments, coolant flows through the second coolantline 156 b from the prime mover (e.g., engine 86, FIG. 4) to theradiator 142, as shown via directional arrow 230 (FIG. 93).

As further shown in FIG. 93, in some embodiments, a shunt line 232extends to a coolant tank 234 which, in some embodiments, is an overflowtank. In some embodiments, a radiator overflow line 236 extends betweenthe radiator 142 and the coolant tank 234. Further, in some embodiments,a coolant tank overflow line 238. In some embodiments, the coolant tankoverflow line 238 is fluidly connected to the coolant tank cap 240. Insome embodiments, the shunt line 232 extends from the first coolant line156 a. In some embodiments, however, the shunt line 232 extends from thesecond coolant line 156 b. In some embodiments, the radiator 142 has noradiator cap and the radiator 142 is filled with coolant via the coolanttank cap 240. In some embodiments, for example as shown in FIG. 93, acoolant line (e.g., first coolant line 156 a) extends from a front ofthe radiator 142. As shown in FIG. 93, in some embodiments, one of thecoolant lines (e.g., second coolant line 156 b) extends from the back ofthe radiator 142. Other configurations can also be utilized. In someembodiments, one or more fans 242 (e.g., electric fans) are used tocirculate air across the radiator fins to help cool the coolant in theradiator. In some embodiments, one or more of the fans 242 arereversible fans and can “pull” or “push” air across the radiator 142 asdesired.

With regard to FIGS. 4 and 31-41, in some embodiments, the ROPS 210comprises two detachable portions: a first detachable ROPS portion 244(FIGS. 40 and 41) and a second detachable ROPS portion 246. In someembodiments, the second detachable ROPS portion 246 is rearward of thefirst detachable ROPS portion 244. In some embodiments, the first andsecond detachable ROPS portions 244, 246 are coupled to one another viaone or more disconnects 36. In some embodiments, the disconnects 36comprise castings that mate with opposing disconnects. As shown in FIG.40, for example, disconnect 36 a is configured to mate with disconnect36 b.

In some embodiments, the ROPS 210 includes one or more lengthwise ROPSmembers 248. In some embodiments, the ROPS 210 includes three lengthwiseROPS members 248 which are generally parallel to one another. In someembodiments, one or more of the lengthwise ROPS members 248 are bowedoutwardly as shown in FIG. 35. As shown in FIG. 41, in some embodiments,the ROPS 210 further includes a front transverse ROPS member 250 and arear transverse ROPS member 252. In some embodiments, one or both of thefront transverse ROPS member 250 and a rear transverse ROPS member 252are bowed. As shown in FIGS. 35 and 41, in some embodiments, the fronttransverse ROPS member 250 is bowed forwardly such that the middle ofthe front transverse ROPS member 250 is forward of the left and rightends of the front transverse ROPS member 250.

In some embodiments, the ROPS 210 includes an A-pillar member 254. Insome embodiments, the A-pillar member 254 is formed form the same pieceof tubing as a lengthwise ROPS member 248. In some embodiments, the ROPS210 includes front V-brace members 256. In some embodiments, the frontV-brace members 256 are coupled to the front transverse ROPS member 250,for example via welding. In some embodiments, the front V-brace members256 are further comprise disconnects and are removably coupled to matingdisconnects. In some embodiments, the front V-brace members 256 have asmaller diameter than the diameter of the A-pillar member(s) 254.

In some embodiments, the ROPS 210 includes an intermediate pillar member258 and a rear pillar member 260, as shown for example in FIGS. 35 and40. In some embodiment, the intermediate pillar member 258 and rearpillar member 260 are coupled via a pillar bracing member 262. In someembodiments, one or both of the intermediate pillar member 258 and rearpillar member 260 include disconnects 36 such that the second detachableROPS portion 246 can be removed from the main frame 212.

In some embodiments, the ROPS 210 includes rear V-brace members 264(FIG. 40). In some embodiments, the rear V-brace members 264 are coupled(e.g., welded) to rear pillar members 260 and rear transverse ROPSmember 250. In some embodiments, the ROPS 210 includes one or moregussets 266 (FIG. 37). In some embodiments, the gussets 266 are weldedto adjacent ROPS members, as shown for example in FIG. 37.

In some embodiments, for example as shown in FIG. 32, the main frame 212includes outer lower frame member(s) 268, front lateral lower framemember(s) 270, rear outer lateral lower frame member(s) 272, rear innerlateral lower frame member 274 (FIG. 34), inner lower frame member(s)276, joining lower frame member(s) 278, rear outer upstanding supportmember(s) 280, front outer upstanding support member(s) 282,intermediate outer upstanding support member(s) 284 (FIGS. 35 and 41),diagonal outer support member(s) 286, rear inner upstanding lowersupport member(s) 288, rear intermediate lateral frame member 290 (FIG.41), rear upper lateral frame member 292 (FIG. 41), rear innerupstanding intermediate support member(s) 294 (FIG. 41), rear outerlengthwise frame member(s) 296, rear outer lateral frame member(s) 298,rear inner lengthwise frame member(s) 300, upper lateral dash supportmember 302 (FIG. 40), lower lateral dash support member 304 (FIG. 40),front upper lengthwise frame member(s) 306 (FIG. 35), front upperlateral frame member 308 (FIG. 34), front upper intermediate lateralframe member 310 (FIG. 41), front upstanding frame member(s) 312 (FIG.32), upper lengthwise dash support member(s) 314 (FIG. 41), frontlengthwise bridging member(s) 316 (FIG. 35), front intermediate supportmember(s) 318 (FIG. 35), front intermediate bridging member(s) 320 (FIG.35), front upper bridging member(s) 322, front intermediate dash supportmember 324 (FIG. 35), steering support member 326 (FIG. 41).

In some embodiments, the frame 12 includes a removable front subframe100 (FIG. 41). In some embodiments, the removable front subframe 100includes coupling locations for the lower A-arms 78, as shown in FIG. 5.In some embodiments, the removable front subframe 100, shown in greaterdetail in FIGS. 94, 97, and 98. In some embodiments, the removablesubframe 100 is coupled (e.g., via fasteners such as bolts) to the frontlateral lower frame member 270 via lower front subframe casting 328(FIGS. 95 and 96). The lower front subframe casting 328 is coupled tothe front lateral lower frame member 270, for example, via welding.

In some embodiments, the removable subframe 100 is coupled to the frontupper A-arm support member 330 (FIGS. 97 and 98) and the frontupstanding frame members 312 via upper front subframe casting 332 (FIGS.97-100). In some embodiments, the upper front subframe casting 332 hasone or more casting features to locate the front upstanding framemembers 312 thereon for attachment thereto (e.g., welding). In someembodiments, the casting features 334 fit inside the inner diameter ofthe respective front upstanding frame member 312 to locate the frontupstanding frame member 312 relative to the upper front subframe casting332.

With further regard to FIG. 40, in some embodiments, the frame 12includes a removable rear subframe 118. In some embodiments, the rearsubframe 118 includes disconnects 36 which couple the rear subframe 118to the rear outer lateral frame member 298, for example via tubesegments 336 extending downwardly from the rear outer lateral framemember 298. In some embodiments, the rear subframe 118 is furthercoupled to the rear inner lateral lower frame member 274, for examplevia lengthwise tube segments 338. In some embodiments, the rear subframe118 comprises one or more laterally extending tube connection members340. In some embodiments, the rear subframe 118 includes one or morerear subframe panels 342 (e.g., stampings), as shown in FIG. 41, to joinadjacent rear subframe members 344.

As shown for example in FIGS. 4-11, 42, and 43, the off-road vehicle 10includes a driveline 350 (FIG. 12). Referring to FIGS. 42 and 43, insome embodiments, the off-road vehicle 10 includes a longitudinallyextending driveshaft 92. In some embodiments, the driveshaft 92 is atwo-piece driveshaft, for example having a first section 92 a and asecond section 92 b, as shown in FIGS. 42 and 43, however, it can alsobe a single piece driveshaft, three piece driveshaft, etc. Where atwo-piece driveshaft 92 is utilized, a bearing mount 352, including abearing such as a ball bearing, can be located at the joint between thefirst section 92 a and the second section 92 b. Further, the bearingmount 352 can be used to secure the driveshaft 92 to the frame 12, whilepermitting rotation of the driveshaft 92. In some embodiments, one ormore portions of the driveshaft 92 extend beneath a portion of theengine 86, as shown in FIG. 42.

In some embodiments, the driveshaft 92 is selectively coupled to a frontdifferential 98. In some embodiments, the front differential 98 caninclude a locker, for example as disclosed in U.S. Pat. No. 7,018,317,the contents of which are herein incorporated by reference.

As further shown in FIGS. 42 and 43, in some embodiments, the off-roadvehicle 10 includes a continuously variable transmission (“CVT”) 354,which includes a drive clutch 356 and a driven clutch 358. The driveclutch 356 and driven clutch 358 have a belt 360 extending therebetween.In some embodiments, the driven clutch 358 is coupled to a transaxle 90.In some embodiments, the transaxle 90 has: one or more forward gears,one or more reverse gears, and neutral. Further, in some embodiments,the transaxle 90 has a park setting. Each of the gear settings can beselected by an operator, for example via gear shift selector 222 (FIG.24).

Turning to FIGS. 44-51, in some embodiments, the engine 86, transmission224, intake assembly 362, and exhaust assembly 364 can be removed fromthe off-road vehicle as an assembly. In some embodiments, the intakeassembly 362 includes an air filter housing 366, having therein one ormore air filters such as paper filters, an air intake conduit 368extending between the filter housing 366 and the intake manifold 370. Insome embodiments, the intake manifold 370 has one or more intake runners140. As show in FIG. 50, for example, in some embodiments, the intakemanifold 370 has three intake runners 140. In some embodiments, theintake manifold 370 has a manifold housing 372, shown in FIGS. 48 and50. In some embodiments, the cross-sectional area of the manifoldhousing 372 is greater nearer the throttle valve 374 than at a distalend portion of the manifold housing 372. As shown in FIG. 48, in someembodiments, the intake manifold 370 and filter housing 366 overlap andthe filter housing 366 is positioned above the intake manifold 370. Insome embodiments, a filter housing support bracket 376 (FIG. 44) iscoupled to the intake manifold 370 and filter housing 366.

In some embodiments, the intake assembly 362 further includes an intakeisolator 384. The intake isolator 384 mates with a portion of the innercowl 386 (FIGS. 53, 82, and 83). In some embodiments, the intakeisolator 384 interfaces with an underside of the inner cowl 386, forexample the right port 388 (FIG. 83) of the inner cowl 386. In someembodiments, the intake isolator 384 has a toroidal cross section. Insome embodiments, the intake isolator 384 is formed from an elastomericmaterial in order to permit the engine/transmission assembly to move alimited amount relative to the inner cowl 386 while a portion of theintake isolator 384 maintains contact with the inner cowl 386. In someembodiments, the intake isolator is formed from a rubber material and,in some embodiments, the intake isolator 384 includes a bellows portion410.

Returning to FIGS. 44-48, and with regard to FIG. 52, in someembodiments, the clutches of the CVT 354 are surrounded by an inner CVTcover 390 and an outer CVT cover 392. In some embodiments, a CVT gasket394 provides a seal between the inner CVT cover 390 and outer CVT cover392. In some embodiments, the outer CVT cover 392 is releasably coupledto the inner CVT cover 390 with one or more CVT cover fasteners 396, forexample spring-type retainers. In this way, the outer CVT cover 390 isremovable from the inner CVT cover 390 without the use of tools (i.e.with hands only).

In some embodiments, the CVT has one or more CVT air intakes. Forexample, as shown in FIG. 52, a first CVT air intake assembly 398 and asecond CVT air intake assembly 400 route air into the space defined bythe CVT covers to facilitate cooling of the CVT. In some embodiments,the first CVT air intake assembly 398 routes air into the CVT via theouter CVT cover 392. Further, as shown in FIG. 52, the second CVT airintake assembly 400 routes air into the CVT via the inner CVT cover 390.The CVT includes a CVT exhaust assembly 402, including a CVT exhaustport 404 and a CVT exhaust duct 406. In some embodiments, the CVTexhaust port 404 is located on the inner CVT cover 390, however, it canbe located on the outer CVT cover 392 or both inner and outer CVTcovers.

As further shown in FIG. 52, in some embodiments, the first air intakeassembly 398 includes a first CVT intake duct 408, a removable outer CVTcover plate 412, and a sealing member 414. In some embodiments, theremovable outer CVT cover plate 412 includes a first intake port 416. Insome embodiments, the removable outer CVT cover plate 412 can be removedfrom the outer CVT cover 392 by rotating the removable outer CVT coverplate 412 in the direction of arrow 418. Further, the removable outerCVT cover plate 412 can be locked into place in rotating the removableouter CVT cover plate 412 in the direction opposite arrow 418. Theremovable outer CVT cover plate 412 includes one or more tabs 420 thatinterface with ramps 422 on the outer CVT cover 392 to lock/unlock theremovable outer CVT cover plate 412 relative to the outer CVT cover 392.The tabs 420 can be located on either the removable outer CVT coverplate 412 or the outer CVT cover 392 and the ramps 422 can also belocated on either the removable outer CVT cover plate 412 or the outerCVT cover 392. In some embodiments, the first CVT intake duct 408interacts with the inner cowl 386 (FIG. 79). In some embodiments, thefirst CVT intake duct 408 interacts with the left port 424 (FIG. 83) ofthe inner cowl 386.

In some embodiments, the second CVT air intake assembly 400 includes asecond CVT intake duct 426, an intake elbow 428, a second CVT intakesealing member 430, and a second intake port 432. In some embodiments,the intake elbow 428 and second intake port 432 have a rectangularcross-section, as shown in FIG. 52. In some embodiments, the second CVTintake duct 426 interacts with the inner cowl 385 (FIG. 83) and, in someembodiments, with the middle port 434 of the inner cowl 386. Withfurther reference to FIG. 83, in some embodiments, the engine 86receives combustion air and the CVT receives cooling air from a spacebetween by the inner cowl 386 and outer cowl 436. Air enters the spacebetween the inner cowl 386 and outer cowl 436 via a grate 438, which isrearwardly facing in some embodiments. In some embodiments, a cowldivider 440 divides the air between the right port 388 on one side andthe middle port 434 and left port 424 on the other side.

In some embodiments, one or both of the CVT covers includes a drain hole442 and drain plug 444.

Returning to FIG. 44, in some embodiments, an outer alternator shroud446 protects the alternator 448 (FIG. 15), alternator drive belt 450,and associated pulleys. In some embodiments, an inner alternator shroud452 (FIG. 46) is provided on the engine side of the alternator 448. Insome embodiments, the alternator drive belt 450 is coupled to the enginecrankshaft (not shown) via a pulley.

With further regard to FIG. 44, in some embodiments, a muffler 378 iscoupled to a muffler support bracket 380 (FIG. 44), for example viafasteners which are fastened to muffler weldment 382, as also shown inFIG. 11. In turn, the muffler weldment 382 is, in some embodiments,welded to the muffler 378.

As shown in FIGS. 49-51, in some embodiments, the engine/transmissionassembly includes an engine cradle member 454, a cradle support 456,cradle bridging member 458, cradle bridging bracket 460, reartransmission support member 462, and transmission support bracket 464.In some embodiments, the cradle support 456 is vibration isolated viafront isolators 466 and the transmission support bracket 464 isvibration isolated via rear isolators 468. In some embodiments, themuffler support bracket 380 is coupled (e.g., welded) to thetransmission support bracket 464. Further, in some embodiments, thetransaxle 90 (FIG. 44) is coupled to the transmission support bracket464, for example via one or more fasteners extending through supportbracket tabs 470. In some embodiments, one or more heat shields 472, 474provide shielding for exhaust pipes 476 (FIG. 48). As shown in FIG. 49,in some embodiments, the engine 86 is coupled to the engine cradlemember 454 in front of the engine 86 and to the cradle bridging member458 behind the engine 86. In some embodiments, the engine cradle member454 has two cradle legs 478; the cradle legs 478 extend under portionsof the engine 86. In some embodiments, the cradle legs 478 are eachwelded to the cradle uprights 480. In some embodiments, the enginecradle member 454 includes hoop member 482. Intake support tabs 484 are,in turn, supported by hoop member 482. In some embodiments an oil filter486 (FIG. 49) is disposed between the engine 86 and the cradle bridgingmember 458.

As shown in FIG. 17, in some embodiments, the rear transmission supportmember 462 is coupled to rear inner lengthwise frame member(s) 300 (FIG.40) via lengthwise frame member brackets 488 (FIG. 17).

In some embodiments, the cradle support 456 (FIG. 51) is coupled tomount member(s) 490 (FIGS. 24 and 26) via front isolators 466 (FIG. 51).In some embodiments, the mount member(s) 490 are welded to the mainframe 212.

Turning to FIG. 21, in some embodiments, the off-road vehicle 10includes a fuel tank 492. In some embodiments, a portion of the fueltank 492 extends rearwardly of a portion of the rear outer upstandingsupport member 280. In some embodiments, a portion of the fuel tank 492extends forwardly to the gear shift selector 222; in some embodiments, aportion of the fuel tank 492 extends forwardly of the bearing mount 352.

Turning to FIGS. 54 and 55, in some embodiments, a steering assembly 494includes a steering wheel 214, a first steering shaft 496, a secondsteering shaft 498, and a third steering shaft 500. In some embodiments,the steering shafts are connected together via universal joints(u-joints) 502. In some embodiments, the steering assembly 494 furtherincludes a steering rack 152 and power steering unit 154 (e.g., electricpower steering or EPS). The steering assembly 494 includes tie rods 504which, in turn, are respectively coupled to front knuckles 506 (FIG.56).

In some embodiments, the steering rack 152 is coupled to a steering rackbracket 502. As shown in the partially exploded view in FIG. 54, thesteering rack bracket 502 is coupled to the front subframe 100 and thefront upper A-arm support member 330.

With regard to FIGS. 56 and 57, in some embodiments, a brake system 508includes a first fluid reservoir 510 and a second fluid reservoir 512.In some embodiments, the second fluid reservoir 512 is a remote fluidfill reservoir. In some embodiments, the first fluid reservoir 510 ispositioned above the master cylinder 514. In some embodiments, brakefluid is supplied to brake calipers, including front brake calipers 516and rear brake calipers 518. In some embodiments, the front calipers 516are each two-piston calipers and the rear calipers 518 are eachsingle-piston calipers, however, the calipers (front and/or rear) can beof any suitable size and have any suitable number of pistons. Further,in some embodiments, the calipers can be integrated with anti-lock brakesensors.

Regarding FIGS. 58-62, 91, and 92, in some embodiments, a frontsuspension assembly 72 includes upper A-arms 80, lower A-arms 78,coil-over springs 68, and front anti-roll bar (ARB) 348. In someembodiments, the upper A-arms 80 are movably coupled to the front upperA-arm support member 330 (FIG. 97), for example via upper A-arm mount(s)346 (FIG. 16). In some embodiments, the front anti-roll bar 348 iscoupled to the lower A-arms 78. Further, the coil-over springs 68 arecoupled to the lower A-arms rearwardly of the upper A-arms 80. In someembodiments, the front anti-roll bar 348 is rotatably coupled to frontARB support member 520 (FIGS. 16 and 29), via front ARB hangar(s) 522(FIGS. 16, 58, 60 and 61). In some embodiments, the lower A-arms 78 arecoupled to the anti-roll bar 348 via front ARB links 524. In someembodiments, the front ARB links 524 include spherical joints 526 at oneor both ends thereof, as shown in FIG. 62, for example. As also shown inFIG. 62, in some embodiments, the spherical joints 526 each have anominal axis (528, 530) though which a fastener is inserted. In someembodiments, the nominal axes 528 and 530 are non-parallel and, in someembodiments, are perpendicular to one another.

In some embodiments, for example as shown in FIG. 61, the front ARBlinks 524 are coupled to a central support 532 which extendsintermediate the forward and rearward arms of the lower A-arm 78. Insome embodiments, respective coil-over springs 68 are further coupled tothe central support 532 outwardly of the location where the front ARBlinks 524 couple to the central support 532.

With regard to FIG. 62, in some embodiments, a front half-shaft 82 iscoupled to a wheel hub 534 such that external splines on the fronthalf-shaft 82 interact with internal splines on the wheel hub 534 tothereby drive the wheel hub 534. In some embodiments, a front knuckle506 includes an inner bearing 536; an inner portion 538 of the wheel hub534 rides on the inner bearing 536. In some embodiments, a brake rotor540 is coupled to the wheel hub 534 inwardly of the flange portions ofwheel hub 534.

In some embodiments, the lower A-arms 78 and upper A-arms 80 includespherical bearings at ends thereof. In some embodiments, the sphericalbearings at the ends of the respective A-arms fit between opposingknuckle arms. In particular, as shown in FIGS. 62, 91, and 92, thespherical bearings of the upper A-arms 80 fit between upper knuckle arms542 and the spherical bearings of the lower A-arms 78 fit between lowerknuckle arms 544. In some embodiments, the inside surfaces of the upperknuckle arms 542 and the inside surfaces of the lower knuckle arms 544are machined surfaces in order to maintain tolerances and permit thedesired fit with the knuckle's interface with the spherical bearings, asshown in FIG. 92. As shown in FIG. 92, the knuckle arms (542, 544)utilize fasteners that are in “double shear”. As further shown in FIG.92, the tie rod arms 546 utilize fasteners that are also in “doubleshear”. With further regard to FIG. 92, in some embodiments, thespherical bearings at the end of the respective A-arms have thereoverrubber boots 548. The rubber boots help prevent foreign material (e.g.,dirt) from intruding into the bearing surface.

Turning to FIGS. 67-84, in some embodiments, the off-road vehicle 10includes one or more body panels, cowls, skid plates, doors. As shown,in some embodiments, the off-road vehicle includes a front bumper panel600, a front grill panel 602, front grill insert 604, central hood panel606, hood insert 608, cornering hood panel 610, front outer fender panel612, front bridging panel 614, rocker panel 616, rear outer fender panel618, firewall panel 620, rear outer fender panel 622, rear bumper panel624, rear ROPS panel 626, rear lower body panel 628, and rear subframepanel 630. In some embodiments, the off-road vehicle 10 further includesan underside panel 632, as shown in FIG. 69.

With additional reference to FIG. 84, in some embodiments, the cargo box202 is removable from the frame 12 (e.g., main frame 212) without tools.As shown in FIG. 84, in some embodiments, the cargo box 202 has aplurality of sidewalls and a floor 634. In some embodiments, the floor634 includes one or more ridges or corrugations 636 to provide strengthto the cargo box 202. In some embodiments, the cargo box 202 is coupled,for example via fasteners 638 (e.g., large wing screws) which can bescrewed in and out with one's hand to secure the cargo box 202 to cargobox frame members 640. In some embodiments, for example as shown in FIG.30, the cargo box frame members 640 extend generally laterally betweenopposing rear outer lengthwise frame members 296. In some embodiments,the cargo box frame members 640 have cargo box frame tabs 642 into whichthe fasteners 638 are screwed (e.g., the cargo box frame tabs includenut plates, etc.).

In some embodiments, the cargo box 202 includes one or more tie-downs644 to which cargo can be secured.

With regard to FIGS. 85-90, 106, and 107, in some embodiments, theoff-road vehicle 10 comprises a floor panel 646, a footwell panel 648,center console 650, upper dash 652, bridging dash panel 654, cornerupright panel 656, gauge panel 658, rear console member 660, andcupholder member 662.

Referring to FIG. 86, in some embodiments, a passenger grab handle 664is coupled at a first end to the upper dash 652 and at a second end to aportion of the frame 12, such as handle support hoop 666, as shown inFIG. 3. In some embodiments, the second end of the passenger grab handle664 is coupled, via fasteners 670, to through-holes 668 (FIG. 3). Thefasteners 670, in turn, are further secured to mating portion of grabhandle portion 664, as shown in FIG. 86. In this way, the passenger grabhandle 664 is secured, in some embodiments to one or more plastic panelsand, additional, to a portion of the frame 12. In some embodiments, thegrab handle 664 is formed in two halves and both halves are formed froma polymeric material.

With reference to FIG. 87, in some embodiments, a glovebox 672 has aglovebox door 674, which is openably coupled, for example with a hinge,to the upper dash 652. In some embodiments, a filler panel 676 can becoupled to the upper dash 652, however, the filler panel 676 can beremoved in favor of one or more accessories, such as GPS navigation,audio system, etc.

Turning now to FIGS. 106 and 107, in some embodiments, a power supplyplug 678 is positioned within the glovebox 672. In some embodiments, thepower supply plug is a 12-volt direct current plug; in some embodiments,the power supply plug is a 120-volt alternating current plug, such as awall-plug.

In some embodiments, one or more USB (universal serial bus) plugs 680are positioned within the glovebox 672. In some embodiments, the USBplugs 680 can provide power for charging cellular phones, etc. In someembodiments, however the USB plugs can permit the operator the abilityto interface with an onboard GPS, modify shock settings or other vehiclecharacteristics, download ride statistics (range, fuel economy, maximumcornering g's, straight line acceleration, lap times, etc.).

With regard to FIGS. 101-105, in some embodiments, the trailing armattachment locations are formed from castings to which respective frametubes are welded. In some embodiments, an outer suspension supportcasting 700 is coupled (e.g., welded) to rear outer lateral lower framemember 272, rear outer upstanding support member 280, outer lower framemember 268, and lower diagonal outer support member 704.

As shown in FIGS. 104 and 105, in some embodiments, the inner suspensionsupport casting 702 is coupled (e.g., welded) to the rear outer laterallower frame member 272, rear inner upstanding lower support member 288,and joining lower frame member 278. As discussed above with respect toother castings, the outer suspension support casting 700 and innersuspension support casting 702 include features which facilitate easyalignment of frame tubes to be welded thereto.

U.S. Pat. No. 8,764,039, titled “Suspension for Vehicle,” filed Apr. 24,2012, having inventors Keller and Seal is hereby incorporated byreference in its entirety. Further, the contents of U.S. Provisionalapplication titled “Camber Adjusting Assembly,” having inventor RobbyGordon, and Application No. 62/208,537, filed Aug. 21, 2015, is hereinincorporated by reference. Additionally, the contents of U.S.Provisional application titled “Universal Wishbone Trailing Arm,” havinginventor Robby Gordon, and Application No. 62/208,531, filed Aug. 21,2015, is also incorporated by reference herein. Additionally, thecontents of U.S. application Ser. No. 15/242,320, titled “UniversalWishbone Trailing Arm,” and U.S. application Ser. No. 15/242,380, titled“Camber Adjusting Assembly,” both having first named inventor RobbyGordon are incorporated by reference herein. U.S. Provisionalapplication titled “Off Road Vehicle,” having inventor Robby Gordon, andApplication No. 62/208,805, filed Aug. 23, 2015, is herein incorporatedby reference. Further, the immediate application claims the benefit ofand priority to Application 62/208,805, titled “Off Road Vehicle,”having inventor Robby Gordon, and filed Aug. 23, 2015. Finally, U.S.62/474,562, filed Mar. 21, 2017, having first named inventor DevinJoseph Danielson is incorporated herein by reference.

Other embodiments of the present disclosure are possible. Although thedescription above contains much specificity, these should not beconstrued as limiting the scope of the disclosure, but as merelyproviding illustrations of some of the presently preferred embodimentsof this disclosure. It is also contemplated that various combinations orsub-combinations of the specific features and aspects of the embodimentsmay be made and still fall within the scope of this disclosure. Itshould be understood that various features and aspects of the disclosedembodiments can be combined with or substituted for one another in orderto form various embodiments. Thus, it is intended that the scope of atleast some of the present disclosure should not be limited by theparticular disclosed embodiments described above.

Thus the scope of this disclosure should be determined by the appendedclaims and their legal equivalents. Therefore, it will be appreciatedthat the scope of the present disclosure fully encompasses otherembodiments which may become obvious to those skilled in the art, andthat the scope of the present disclosure is accordingly to be limited bynothing other than the appended claims, in which reference to an elementin the singular is not intended to mean “one and only one” unlessexplicitly so stated, but rather “one or more.” All structural,chemical, and functional equivalents to the elements of theabove-described preferred embodiment that are known to those of ordinaryskill in the art are expressly incorporated herein by reference and areintended to be encompassed by the present claims. Moreover, it is notnecessary for a device or method to address each and every problemsought to be solved by the present disclosure, for it to be encompassedby the present claims. Furthermore, no element, component, or methodstep in the present disclosure is intended to be dedicated to the publicregardless of whether the element, component, or method step isexplicitly recited in the claims.

The foregoing description of various preferred embodiments of thedisclosure have been presented for purposes of illustration anddescription. It is not intended to be exhaustive or to limit thedisclosure to the precise embodiments, and obviously many modificationsand variations are possible in light of the above teaching. The exampleembodiments, as described above, were chosen and described in order tobest explain the principles of the disclosure and its practicalapplication to thereby enable others skilled in the art to best utilizethe disclosure in various embodiments and with various modifications asare suited to the particular use contemplated. It is intended that thescope of the disclosure be defined by the claims appended hereto

Various examples have been described. These and other examples arewithin the scope of the following claims.

What is claimed is:
 1. An off-road vehicle comprising: a frame,including at least one cargo box support member; a suspension movablycoupled to the frame; a passenger compartment; an engine; a transmissionoperatively coupled to the engine; and a cargo box, the cargo boxcomprising a floor and a plurality of upwardly extending sidewalls,wherein at least a portion of the cargo box floor extends over the atleast one cargo box support member and wherein the cargo box isremovably coupled to the at least one cargo box support members and isremovable from the off-road vehicle via the removal of fewer than eightfasteners.
 2. An off-road vehicle comprising: a frame, including atleast one cargo box support member; a suspension movably coupled to theframe; a passenger compartment; an engine having an engine block; atransmission operatively coupled to the engine; and an engine cradle,the engine cradle having a first portion extending forwardly of theengine block and a second portion extending rearwardly of the engineblock, wherein at least a portion of the engine cradle extends under theengine block.